Part 1

LF1A TRANSFER: TRANSFER ASSEMBLY: DISASSEMBLY

1. REMOVE DYNAMIC DAMPER

(a) Remove the bolt, 2 washers and dynamic damper from the rear transfer case.

2. REMOVE TRANSFER CASE PLUG

(a) Using a 6 mm hexagon socket wrench, remove the 2 case plugs and 2 O-rings from the front transfer case.

3. REMOVE FILLER PLUG

(a) Using a 10 mm hexagon socket wrench, remove the filler plug and gasket from the rear transfer case.

4. REMOVE TRANSFER DRAIN PLUG

(a) Using a 10 mm hexagon socket wrench, remove the drain plug and O-ring from the front transfer case.

5. REMOVE TRANSFER CASE BREATHER PLUG

(a) Remove the breather plug from the front transfer case.

6. REMOVE NO. 2 TRANSFER CASE PLUG

(a) Using a 17 mm straight hexagon wrench, remove the case plug and gasket from the rear transfer case.

7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, hold the companion flange in place.

SST : 09213-58014

SST : 09330-00021

HINT
Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.

(b) Remove the companion flange bolt and companion flange from the transfer assembly.

Text in Illustration

8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST and a hammer, loosen the staked part of the transfer output shaft nut.

SST : 09930-00010

NOTICE:
* Completely loosen the staked part of the transfer output shaft nut.
* Do not damage the threads of the No. 1 differential case.
* Use SST with the tapered surface facing the No. 1 differential case.
* Do not grind the end of SST with a grinder or other tool.

(b) Using SST, hold the companion flange in place.

SST : 09330-00021

SST : 09950-30012

09955-03040

Text in Illustration

(d) Using SST, remove the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03040

Text in Illustration

9. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL

(a) Using SST, remove the oil seal.

SST : 09308-00010

NOTICE:
Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.

10. REMOVE NO. 1 DIFFERENTIAL CASE HOLE SNAP RING

(a) Using needle-nose pliers, remove the snap ring from the extension housing.

11. REMOVE TRANSFER EXTENSION HOUSING

(a) Remove the 11 bolts and bracket.

(b) Using an oil pan seal cutter, remove the extension housing.

NOTICE:
Be careful not to damage the contact surface of the extension housing or rear transfer case.

12. REMOVE NO. 1 TRANSFER THRUST BEARING RACE

(a) Using a screwdriver, remove the bearing race from the extension housing.

Text in Illustration

HINT
Tape the screwdriver tip before use.

NOTICE:
Be careful not to damage the surface which contacts the bearing race.

13. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING

(a) Using SST and a press, remove the bearing (outer race) from the extension housing.

SST : 09950-60010

09951-00460

SST : 09950-70010

09951-07100

HINT
The bearing (inner race) is removed from the No. 1 differential case sub-assembly.

14. REMOVE TRANSFER OUTPUT SHAFT WASHER

(a) Remove the 2 shaft washers from the No. 1 differential case.

15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING

(a) Remove the bearing from the No. 1 differential case.

16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE

(a) Remove the bearing race from the No. 1 differential case.

17. REMOVE TRANSFER OUTPUT SHAFT SHIM

(a) Remove the shim from the No. 1 differential case.

18. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the No. 1 differential case from the rear transfer case.

19. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING

(a) Using SST, remove the bearing (inner race) from the No. 1 differential case.

SST : 09950-00020

SST : 09950-00030

Text in Illustration